1 BIONICO B IOGAS MEMBRANE REFORMER FOR DECENTRALIZED H 2 PRODUCTION Call: H2020-JTI-FCH-2014-1 Topic: FCH-02.2-2014 Decentralized hydrogen production from clean CO 2 -containing biogas 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
2 S UMMARY BIONICO aims at developing a novel reactor configuration at a larger scale to produce H 2 from biogas production power plant based on: Design, develop and test a new concept reactor integrating hydrogen production and purification on a single unit Design, develop and testing of a catalytic membrane reactor for the production of highly-purity hydrogen from biogas, scaling up new H 2 selective membranes and catalyst production Develop a flexible system (including the advance control and BoP components) capable of producing pure hydrogen from biogas of different composition s in a unique reactor system. The main idea of BIONICO is to design and demonstrate an efficient biogas-to-hydrogen conversion system at real plant conditions (in the ENC Landfill plant at Chamusca, Santarém, Portugal) using process intensification. 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
3 C ONCEPT Pure H 2 End Users B IONICO P ROCESS Biogas plant Raw Biogas Sulfur Removal 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
4 W HY B IONICO ? h Offgas 0.59 C ONVENTIONAL S YSTEM REFORMER PSA HT-WGS LT-WGS SR / ATR ( H 2 Purification ) (350°C) (200°C) HYDROGEN (800°C) Sulphur BIOGAS PLANT Removal M EMBRANE R EACTOR (500-600°C) Retentate h >0.70 Reference Case Results units SR ATR Biogas feed Nm 3 /h 35.7+14.6 47.0 Two reference cases (based on SR and Total Biogas Input kW 221 207 ATR) are identified to benchmark the System efficiency % LHV 59.2 55.4 Hydrogen delivery performance of the BIONICO concept bar 13.3 13.3 pressure Equipment costs € *h/Nm 3 14520 12342 Hydrogen € /Nm 3 0.408 0.398 production cost The target of BIONICO is a system efficiency above 70% LHV , which is about 20% higher than SR (59% LHV ). The higher efficiency together with equipment savings will end up in lower hydrogen production costs. 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
5 P ARTNERSHIP Multidisciplinary and complementary team: 8 top level European organisations from 7 countries including: 3 Research Institutes and Universities and 4 representative top industries in different sectors (from catalyst to membranes to chemical and process engineering, etc.) POLIMI, Italy TU/e, The Netherlands Abengoa, Spain Tecnalia, Spain Johnson Matthey, UK ENC Energy, Portugal Rauschert, Germany Quantis, Switzerland 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
6 W ORK STRUCTURE 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
7 P ARTNERSHIP S YNERGIES 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
8 N OVEL C ATALYST G OAL Development of highly active reforming catalysts to produce hydrogen from diverse biogas mixture coupled with steam and air in a fluidised bed regime. F IRST Y EAR A CTIVITIES PGM doped alumina catalysts have been tested under biogas reforming conditions for dry, steam or auothermal reforming Coke formation resistance improvement A CHIEVEMENTS 1 st generation catalyst 2 nd generation catalyst able to work under fluidisation regime and at low temperature 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
9 N OVEL M EMBRANE & S UPPORT G OAL Development of Pd based tubular supported membranes, for application in biogas reforming catalytic membrane reactors F IRST Y EAR A CTIVITIES Preparation of porous ceramic tubes of different diameters and materials for their use as supports for thin Pd-based membranes Manufacturing of thin film (<5 µm thick) Pd-Ag and Pd-Ag-Au membranes on top of the ceramic supports. Development of new finger-like porous asymmetric ceramic supports in which one of the ends of the tube is a closed porous part. 1 st generation thin film Pd-alloy (< 5 µm) supported membranes 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
10 N OVEL M EMBRANE & S UPPORT G OAL Development of Pd based tubular supported membranes, for application in biogas reforming catalytic membrane reactors A CHIEVEMENTS 1 st generation membrane & support Installation of a new plating system for preparation of >40 cm long membranes. 2 nd generation supports are finger-like porous tubes. Thin Pd-Ag layers have been deposited onto the first 50 cm long finger-like supports 2 nd generation thin film Pd-alloy supported membranes 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
11 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. F IRST Y EAR A CTIVITIES Testing separately the stability and performance of the membranes and catalyst delivered by TECNALIA and JM. Membranes tested in pure gas conditions such as nitrogen, hydrogen and mixtures containing CO or H 2 S Catalyst reaction kinetics are being obtained to include in the model Membrane & catalyst integrated in a fluidized bed reactor Identify the sealing method to be used in BIONICO The effect of H2S on the performance of PdAg and PdAgAu membranes are studied 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
12 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. A CHIEVEMENTS Interaction between membrane and catalyst. The results showed that the hydrogen permeance is not affected by the presence of the catalyst The sealing of the tested membranes are improved with specific sized ferrules according to the membrane size 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
13 L AB S CALE R EACTOR G OAL Definition of the lab scale reactors performances and identification of the best design for prototype pilot. A CHIEVEMENTS Membranes including Au showed better resistance to the exposure to H 2 S: H 2 permeance decrease was dependent on the concentration of H 2 S 1 0.9 Perm H2S /Perm 0 (-) 0.8 0.7 0.6 0.5 PdAg E505 PdAg PdAgAu (5% Au) E505 PdAgAu (5%au) 0.4 E506 PdAgAu (7%au) PdAgAu (7% Au) 0.3 0 5 10 15 20 H 2 S [ppm] 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
14 P ROTOTYPE R EACTOR G OAL Final design and construction of MR prototype for the production of approximately 100 kg/day of pure hydrogen F IRST Y EAR A CTIVITIES Preliminary design of the prototype catalytic membrane reactor at large Retentate scale including control system design PURE ATR-MR HYDROGEN H 2 Preliminary design of the balance of plant Vacuum Pump HX-4 HX-2 Air+H 2 O CMP BG Air brn BIOGAS Exhaust Burner Sep HX-1 HX-0 Sep water Air ATR rec. H 2 O CMP Air H 2 O feed P-1 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
15 I NTEGRATION &T ESTING AT B IOGAS P RODUCTION S ITE G OAL Final evaluation of the innovative process to directly produce pure hydrogen in a real biogas production site (ENC Landfill plant in Chamusca) F IRST Y EAR A CTIVITIES Definitions of input needed for starting the plant licensing procedure Evaluating the integration of the prototype reactor in the overall BIONICO system at biogas production site Chamusca Chamusca Landfill plant Biogas cleaning unit 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
16 L IFE C YCLE A SSESSMENT & S AFETY I SSUES G OAL Development strategy towards sustainable solutions and provide guidance on how operate the reactor prototype under safe conditions. F IRST Y EAR A CTIVITIES Refined goal & scope of LCA analysis, in particularly, with further clarifications with regard to: (i) reference systems (baseline), i.e., SMR and ATR, (ii) level of details of inventory modeling and (iii) system boundaries Improved data collection for key data points, especially related to functional unit, biogas input, conversion efficiency, energy and water use as well as direct GHG emissions during conversion processes Performed 1st screening comparative LCA analysis between BINICO CMR and reference technologies 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
17 L IFE C YCLE A SSESSMENT & S AFETY I SSUES G OAL Development strategy towards sustainable solutions and provide guidance on how operate the reactor prototype under safe conditions. A CHIEVEMENTS 1 st screening LCA modeling : BIONICO CMR vs reference technology 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
18 L IFE C YCLE A SSESSMENT & S AFETY I SSUES G OAL Development strategy towards sustainable solutions and provide guidance on how operate the reactor prototype under safe conditions. A CHIEVEMENTS Screening LCA results: BIONICO CMR performs better than reference systems 31/10/2016 Disclosure or reproduction without prior permission of BIONICO is prohibited
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